METHOD FOR SEPARATING METALS AND ALCOHOLS FROM AN EMULSIFIED ORGANIC/AQUEOUS EFFLUENT

Abstract: A method for treating an emulsified organic/aqueous effluent stream that comprises water, at least one metal complex and alcohol. The treatment comprises the steps of: separating the emulsified organic/aqueous effluent stream into an aqueous phase stream which comprises water, at least one metal complex, and residual alcohol and an organic phase stream which comprises alcohol, residual water and a metal complex; separating the aqueous phase stream into a metal and organic enriched stream and aqueous stream; recycling the metal and organic enriched stream to the emulsified organic/aqueous effluent stream; and discharging the aqueous stream.

Description: METHOD FOR SEPARATING METALS AND ALCOHOLS FROM AN EMULSIFIED ORGANIC/AQUEOUS EFFLUENT The present invention relates generally to a method for separating heavy metals, such as zinc, and alcohols from an emulsified organic/aqueous effluent by means of a reverse osmosis membrane and/or a pervaporation membrane. BACKGROUND OF THE INVENTION The dispose of emulsified organic/aqueous effluent streams from chemical processes is of particular concern during the manufacture of lube oil additives, such as metal dialkyldithiophosphates. Metal dialkyldithiophosphate salts preferably comprise a Group IIB metal or a metal selected from the group consisting of copper, molybdenum, antimony, zinc and mixtures thereof. The preferred lube oil additive is zinc dialkyldithiophosphate (ZDDP). The alkyl groups preferably comprise C 3 to C 10 alkyls. Therefore, the emulsified organic/aqueous effluent streams generated from these processes include, together with water, substantial amounts of environmentally undesirable materials, i.e., heavy metal complexes and alcohols. Conventional methods for treating emulsified organic/aqueous effluent streams containing a metal complex and alcohols typically utilize phase separation to produce a saturated aqueous phase and a saturated alcohol phase. The aqueous phase, which comprises a metal complex, water and residual alcohol, is typically discharged untreated into the plant's sewer system. The alcohol phase is typically sent on to hazardous waste disposal. However, conventional phase separation of the emulsified organic/aqueous effluent stream is incapable of reducing the levels of metal complex discharged together with the aqueous phase to acceptable environmental standards. The present invention overcomes these strict environmental standards and also provides for the recycling of the alcohol upstream of the process which enhances the cost effectiveness of the overall process and avoids hazardous waste disposal of the alcohol. The present invention also provides many additional advantages which shall become apparent as described below. SUMMARY OF THE INVENTION The present invention relates to a method for separating metal complexes, such as zinc, and alcohols from an emulsified organic/aqueous effluent by phase separation followed by contacting the aqueous phase with a reverse osmosis membrane so that water passes through the membrane, as permeate, and the metal complex and residual alcohols are recycled to the phase separator, as retentate. Alternatively, the aqueous phase may be contacted with the reverse osmosis membrane, as described above, while the organic phase is contacted with a pervaporation membrane so that water passes through the membrane, as permeate, and metal complexes and residual alcohols are recycled to the upstream metal dialkyldithiophosphate process, as retentate. The uniquely combined reverse osmosis and pervaporation membrane system of the present invention can also be used to treat an emulsified organic/aqueous effluent stream that comprises primarily water and alcohol. Other and further objects, advantages and features of the present invention will be understood by reference to the following specification in conjunction with the annexed drawings, wherein like parts have been given like numbers. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic representation of the separation process according to one embodiment of the present invention wherein a reverse osmosis membrane is used to treat an aqueous phase stream so as to separate alcohol and zinc from water; Fig. 2 is a schematic representation of the separation process according to another embodiment of the present invention wherein a reverse osmosis membrane is used to treat an aqueous phase stream and a pervaporation membrane is used to treat an alcohol phase stream; Fig. 3 is a graph plotting membrane flux verses volume reduction (VR) with no pH adjustment for the separation of alcohol and zinc from an emulsified organic/aqueous effluent stream under reverse osmosis conditions; and Fig. 4 is a graph plotting membrane flux verses volume reduction (VR) with pH adjustment for the separation of alcohol and zinc from an emulsified organic/aqueous effluent stream under reverse osmosis conditions. DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention can best be described by referring to the attached drawings wherein Fig. 1 depicts a method for separating metal complexes, such as zinc, and alcohols from an emulsified organic/aqueous effluent by phase separation followed by contacting a reverse osmosis membrane with the aqueous phase so that water passes through the membrane, as permeate, and the metal complex and residual alcohols are recycled tc the phase separator, as retentate. The emulsified organic/aqueous effluent typically comprises an emulsified two-phase mixture of alcohol and water. An emulsified organic/aqueous effluent stream separated from a crude metal dialkyldithiophosphate product is sent via conduit 2 to a phase separator or coalescer 4. The emulsified organic/aqueous effluent stream typically comprises water, a metal complex and alcohols. Once the emulsified organic/aqueous effluent stream is contained within phase separator 4 it separates by gravity settling into a saturated aqueous phase stream 6 which comprises water, a metal complex and residual alcohol and a saturated organic phase stream 8 which comprises alcohol, residual water and a metal complex. Thereafter, aqueous phase stream 6 is passed from separator 4 via conduit 10, interface controller valve 12, and pump 14 to separator unit 14. Aqueous phase stream 6 contacts membrane 16 under reverse osmosis conditions such that aqueous phase stream 6 is separated into a metal and alcohol enriched retentate and an aqueous permeate. The metal and alcohol enriched retentate is thereafter recycled to emulsified organic/aqueous effluent stream 6 via recycle conduit 20. The aqueous permeate is discharged from separator 14 to conventional plant sewer systems via conduit 18. Reverse osmosis is a process that reverses , by the application of pressure (i.e., a pressure in the range between about 2.068 x 10 5 N/m 2 to about 1.379 x 10 7 N/m 2 ), the flow of water in the natural process of osmosis so that it passes frcn the mere concentrated to the more dilute solution. Reverse osmosis membrane 16 is preferably a solvent resistant membrane, such as an interfacially polymerized polyamide-based membrane. One preferred polyamide-based membrane is an interfacially synthesized reverse osmosis membrane comprising a microporous substrate and an ultra-thin membrane covering the substrate, wherein the ultra-thin membrane comprises a crosslinked aromatic polyamide. Some examples of solvent resistant, reverse osmosis, membranes are set forth in U.S. Patent Nos. 4,857,363 (Sasaki et al.), which issued on August 15, 1989, 5,051,178 (Uemura et al.), which issued on September 24, 1991, 4,758,343 (Sasaki et al.), which issued on July 19, 1988, and 4,761,234 (Uemura et al.), which issued on August 2, 1988. Still other interfacially polymerized reverse osmosis membranes are disclosed in U.S. Patent Nos. 4,039,440 (Cadotte), which issued on August 2, 1997, 4,277,344 (Cadotte), which issued on July 7, 1981, 4,769,148 (Fibiger et al.), which issued on September 6, 1988, and 4,859,384 (Fibiger et al.), which issued on August 22, 1989. All of the aforementioned U.S. Patents are incorporated herein by reference. Any membrane which is capable of separating metals and alcohols from water by permeating water and retaining the metals and alcohols is also contemplated hereby. Alternatively as shown in Fig. 2, the reverse osmosis membrane may be contacted with the aqueous phase stream, as described above, while a pervaporation membrane is contacted with the organic phase stream so that water passes through the membrane, as permeate, and metal complexes and residual alcohols are recycled to the upstream process, as retentate. That is, an emulsified organic/aqueous effluent stream produced from a metal dialkyldithiophosphate reaction process is separated from the crude metal dialkyldithiophosphate product by vacuum flask 30, wherein the metal dialkyldithiophosphate product is removed as bottoms and a crude aqueous stream is taken overhead. The crude emulsified organic/aqueous effluent stream is passed to a second distillation column 34 via conduit 32 wherein an emulsified organic/aqueous effluent stream is taken as bottoms and theresafter passed to phase separator or coalescer 4 via conduit 2 for phase separation. The overhead components (i.e., alcohol and water) taken from distillation column 34 are recycled via conduit 36 to conduit 32. The emulsified organic/aqueous effluent stream disposed within phase separator 4 separates by gravity settling into an aqueous phase stream 6 which comprises water, at least one metal complex, and residual alcohol and an organic phase stream 8 which comprises alcohol, residual water and a metal complex. Thereafter, aqueous phase stream 6 is passed from first separator 4 via conduit 10 and pump 14 to separator unit 1 . Aqueous phase stream 6 contacts membrane 16 under reverse osmosis conditions such that it is separated into a metal and alcohol enriched retentate and an aqueous permeate. The metal and alcohol enriched retentate is thereafter either recycled to the aqueous phase ' stream via conduits 20 and 36, or recycled upstream of second separator 38 via conduit 40. The aqueous permeate is discharged from separator 14 to a conventional plant sewer system via conduit 18. The organic phase stream 8 from phase separator 4 is delivered to second separator unit 38 via conduit 42 and pump 44. Organic phase stream 8 thereafter contacts a membrane separator 46 under pervaporating conditions wherein it is separated into an organic-rich stream, as retentate, and an organic-poor stream, as permeate. The organic-poor stream is then recycled to either conduit 10 which is upstream of first separator unit 14 via conduits 48 and 50 or to conduit 42 upstream of second separator unit 38. The organic-rich stream is recycled via conduit 52 for use as a reactant in the synthesis of the crude metal dialkyldithiophosphate product. Pervaporation separations are typically run at generally higher temperatures than perstraction and rely on vacuum on the permeate side to evaporate the permeate from the surface of the membrane and maintain the concentration gradient driving force which drives the separation process. Pervaporation membranes are polymeric solubility membranes in the peculiar state of anisotropic swelling which is a consequence of the phase change involved. The choice of the membrane polymer has direct bearing on the separation effect to be achieved, as is illustrated by aqueous-organic separations , which may be directed at selective removal of water (dehydration) , or at selective removal and concomitant enrichment of the organic component (the ambivalent nature of pervaporation) . Three distinct types of membrane polymers for pervaporation of aqueous-organic solutions can be identified. These include: (1) glassy (amorphous) polymers that preferentially permeate water; (2) elastomeric polymers that interact preferentially with the organic solution component; and (3) ion exchange membranes that may be view as crosslinked electrolytes. Because liquid mixtures cannot be separated using porous membranes, pervaporation membranes must be either fully dense membranes or membranes having a dense top layer, either asymmetric or composite. Pervaporation membrane 46 (i.e., a dehydration pervaporation membrane) is preferably selected from the group consisting of: polyvinyl alcohol (crosslinked or non-crosslinked) , polyacrylate salt on polyethersulfone, crosslinked composite of a polysaccharide, grafted polyethylene, polypropylene, poly(n-vinylpyrrolidone-co-acrylonitrile, ion-exchange resin/pendant acid groups, and a blend of polyvinyl alcohol, polyacrylic acid and nylon. Some examples of pervaporation membranes are set forth in U.S. Patent Nos. 4,755,299 (Bruschke) , which issued on July 5, 1988, 5,059,327 (Takegami), which issued on October 22, 1991, 4,728,431 (Nagura et al.), which issued on March 1, 1988, and 5,009,783 (Bartels), which issued on April 23, 1991. All of the aforementioned patents are incorporated herein by reference. Any membrane which is capable of dehydrating an organic-rich stream by permeation of water therethrough and retention of the organics is also contemplated hereby. The most prominent pervaporation material is polyvinyl alcohol (PVA). It is preferable to provide pervaporation membranes wherein the polyvinyl alcohol has been crosslinked with, for example, maleic acid, and an aliphatic polyaldehyde. Such crosslinked PVA membranes are disclosed in U.S. Patent Nos. 4,935,144 (Reale, Jr. et al.), which issued on June 19, 1990, and 4,802,988 (Bartels et al. ) , which issued on February 7, 1989, both of which are incorporated herein by reference. A typical aqueous effluent treated in accordance with the present invention includes the following constituents set forth in Table 1 below: TABLE 1 Composite Permeate Aqueous Phase Compound Feed at 50% VR at 50% VR 10 Sec. Butanol 1.73 wt% 0 1.36 Isobutanol 3.01 wt% 0 1.88 MIBC 0.11 wt% 0 Trace Isoamyl 0.18 wt% 0 0.07 N-amyl 0.24 wt% 0 0.12 zinc 28 ppm 0.5 79 TOC 29,000 ppm 1200 Not Avail, Note: MIBC denotes methylisobutyl carbinol, TOC denotes total organic carbon. EXAMPLE 1 A reverse osmosis application test aimed at separating zinc as well as a large fraction of alcohols from an aqueous phase stream previously separated from an emulsified organic/aqueous effluent discharged from a zinc dialkyldithiophosphate process was conducted to determine zinc and alcohol retention properties of Filmtec's FT-30 SW reverse osmosis membrane. The tests at 0% volume reduction (VR) (i.e., no permeate withdrawal) were positive, showing a zinc rejection of 98.7% and alcohol rejection of 93% by the membrane. The permeate flux at 0% VR was ca 2.4 gfd at 600 psig (4.1 X 10 6 N/m 2 ) . Set forth below in Table 2 is an analyses of the aqueous phase stream which has been subjected to membrane separation under reverse osmosis conditions. Table 2 Comp. 0% 25% 50% Aq. Phase Permeate Feed Perm. Perm. Perm. 50% Cone. at 50% Reject. PH 3.73 3.3 3.22 3.22 4.05 - - TOC (mg/L) 29000 5500 4300 85 300,000* 1200 95.9+ zinc (mg/L) 25 0.33 0.19 0.18 50 0.21 99.6- BOD* - - - - - 4100 Notes: * The high number is probably due to incomplete separation of the free alcohol phase. + Calculated from feed TOC and composite permeate TOC. - Calculated from 50% concentration of zinc and composite permeate zinc. BOD5 denotes biological oxygen demand. The separation data in Table 2 demonstrates good rejection of zinc and the alcohols (i.e., 99.6% and 95.9%, respectively). When compared with separation data from phase separation alone, these figures suggest an improvement in the rejection of both the zinc and the alcohols upon concentration of the feed. EXAMPLE 2 A test was conducted using a Filmtec FT-30 SW membrane (i.e., 2.5 inches (6.35 cm) x 14 inches (35.56 cm) spiral wound membrane). An aqueous phase stream previously separated from an emulsified organic/aqueous effluent stream discharged from a zinc dialkyldithiophosphate process was passed over the membrane at both 600 psig (4.1 x 10 6 N/m 2 ) and 800 psig (5.5 x 10 6 N/m 2 ) at 0% volume reduction. The results are set forth below in Table 3. TABLE 3 Elapsed Temp. Press. Press. Perm. Rate Flux Rejection Time(hours) (°F) (psig) (psig) (ml/min.) (USgfd) (%) 0 74 820 780 100 3.6 53.2 0.5 76 820 780 87 3.2 54.0 1.0 76 820 780 82 ' 3.0 54.4 2.0 76 820 780 75 2.7 55.4 3.75 77 820 780 74 2.7 55.0 4.5 72 620 580 38 1.4 53.1 9.5 76 830 770 62 2.2 53.8 9.5 75 620 580 38 1.4 - 25.5 72 620 580 25 0.9 50.7 25.8 77 830 770 44 1.6 - 32.0 76 615 585 22 0.8 52.8 32.0 77 830 770 36 1.3 - 54.0 80 630 570 17 0.6 63.7 54.75 76 835 765 30 1.1 66.7 The permeate flux dropped after approximately 25 hours to 1.0 gfd and 1.6 gfd at 600 psig (4.1 x 10 6 N/m 2 ) and 800 psig (5.516 x 10 6 N/m 2 ), respectively. The pH of this Example 2 was 3.7, compared to a pH of 4.5 for Example 1. EXAMPLE 3 A concentration test was then carried out over a period of 32 hours, with volume reduction increased from 0% to 53%, as shown in Table 3 above. Most of the concentration tests were carried out at an average transmembrane pressure of 800 psi (5.5 x 10 6 N/m 2 ). This relatively high operating pressure was selected in view of the low overall permeate flux obtained. A pressure verses flux study was also conducted at a number of volume reductions (i.e., 0%, 36% and 50%). The pressure was adjusted over the range of 400 psi (2.8 x 10 6 N/m 2 ) to 1,000 psi (6.9 x 10 6 N/m 2 ). As to be expected, for a given VR, the flux increased linearly with operating pressure. At 800 psi (5.5 x 10 6 N/m 2 ), the flux decreased from 1.6 gfd at 0% VR to 1.3 gfd at 9% recovery and remained reasonably constant at between 1.1 and 1.2 gfd as the volume reduction was increased from 9% to about 50%. The constant flux, albeit low, can be explained by a relatively constant osmotic pressure exerted by the aqueous phase. As the wastewater becomes saturated (presumably at approximately 9% VR) , the alcohol begins to separate into a second phase which will not contribute to osmotic pressure. The highest achievable permeate flux during the concentration test was 1.5 gfd which was obtained at a transmembrane pressure of 1,000 psi (6.9 x 10 6 N/m 2 ) . EXAMPLE 4 Continuous membrane testing of an aqueous phase stream previously separated from an emulsified organic/aqueous effluent stream from a zinc dialkyldithiophosphate process using an interfacially polymerized polyamide-based, solvent resistant, reverse osmosis, SU-810 membrane, manufactured by Toray Industries, Inc. , of Tokyo, Japan, demonstrated excellent separation properties and stable membrane flux. As shown in Table 4 below and Fig. 3, the TOC (i.e., alcohol) rejection was approximately 90%, the zinc rejection was approximately 98%, and the permeate flux was relatively stable at approximately 3 gfd at 800 psig (5.5 x 10 6 N/m 2 ). Table 4 (No pH Adjustment) 0% VR 25% VR 40% VR Feed Cone. Perm. Rej. % Cone. Perm. Rej. % Cone. Perm. Rej. % PH 3.77 3.77 3.33 - 3.77 3.32 - 3.83 3.30 - Cond. 213 213 136 36.2 234 137 41.5 250 144 42.4 Zinc 27 24 0.33 98.6 29 0.32 98.9 36 0.37 99.0 TOC 36000 34000 1400 95.9 43000 2300 94.7 53000 3300 93.8 Iron 83 62 0.9 98.5 . . - - . . R| 3.2 3.6 0.2 94.4 4.2 0.2 95.2 5.0 0.2 96.0 Flux 3.7 3.83 3.83 Table 4 Continued 60% VR 80% VR 90% VR Feed Cone. Perm. , Rej. % Cone. Perm. Rej. % Cone. Perm. Rej. % pH 3.77 3.96 3.28 - 4.11 3.34 - 4.22 3.27 - Cond. 213 289 148 48.8 390 153 60.8 565 160 71.7 Zinc 27 49 0.41 99.2 81 0.52 99.4 120 2.1 98.3 TOC 36000 71000 6000 91.5 96000 8000 91.7 92000 12000 87.0 Iron 83 - - - - - - - - - Rl 3.2 6.0 0.6 90.0 7.2 0.8 88.9 7.6 1.2 84.2 Flux 3.10 2.82 2.99 Note: Conductivity was measured in μS/cm. Zinc, TOC and Iron were measured in mg/L. Refractive Index (Rl) was measured in Brix. Flux was measured in USgfd. Example 5 As demonstrated in Fig. 4 and Table 5, pH adjustments of the aqueous phase stream to 6.0 resulted in partial precipitation of zinc and iron, higher volume reduction factors required to form the free alcohol ( " 70% VR) , poorer alcohol rejections (i.e., 74- 87%) and lower flux (i.e., 1.9 gfd verses 3.1 gfd from the straight sample). The lower flux is most likely due to higher osmotic pressures. These tests confirmed that there were no clear advantages in adjusting the pH of the water upwards prior to reverse osmosis treatment. Table 5 (pH Adjustment) 0%VR 10%VR 20%VR Cone. Perm. Rej. % Cone. Perm. Rej. % Cone. Perm. Rej. % pH 5.77 5.89 - 6.07 5.88 - 6.06 5.87 - Cond. 704 28 96.0 761 30.000 96.1 816 32 96.1 Zinc 5.84 0.025 99.6 5.8 0.032 99.4 6.7 0.038 99.4 TOC 33000 5500 83.3 34000 6000 82.4 37000 7000 81.1 Iron 2.6 <0.01 - - - - - - - Rl 2.6 0.0 100.0 2.6 0.2 92.3 3.0 0.2 93.3 Flux 2.82 2.74 2.61 Table 5 Continued 30% VR 40% VR 50% VR Cone. Perm. Rej. % Cone. Perm. Rej. % Cone. Perm. Rej. % pH 6.02 5.87 - 6.10 5.92 - 5.96 5.66 - Cond. 901 33 96.3 1122 55 95.1 1359 64 95.3 Zinc 6.8 0.036 99.5 7.7 0.054 99.3 8.83 0.121 98.6 TOC 45000 6000 86.7 - - - 45000 7500 83.3 Iron - - - - - - - - - Rl 3.4 0.2 94.1 3.6 0.2 94.4 4.0 0.2 95.0 Flux 2.50 2.33 2.33 Table 5 Continued 60% VR 70% VR Cone. Perm. Rej. % Cone. Perm. Rej. % PH 5.84 5.53 - 5.80 5.30 - Cond. 1692 79 95.3 2090 105 95.0 Zinc 10.90 0.148 98.6 14.30 0.176 98.8 TOC 55000 12000 78.2 69000 18000 73.9 Iron - - - - - - Rl 4.8 0.6 87.5 5.6 1.0 82.1 Flux 2.20 1.90 Upon formation of free alcohol at a VR of 60%, a highly stable alcohol/water emulsion was formed. Using a separatory funnel, the reverse osmosis concentrate formed a thin alcohol film on top, a bulk phase containing a yellowish haze (i.e., very fine alcohol droplet dispersion) and a small clear water phase at the bottom. This emulsion remained stable for many weeks. In order to ensure optimum performance of the reverse osmosis membrane and the adequate functioning of interface control instruments throughout the process it is recommended that this alcohol emulsion be broken, preferably by mechanical means (e.g. , coalescence of the alcohol droplets) . Laboratory tests showed that centrifugation was not effective. Heating of the emulsion also did not improve the phase separation of the alcohol. Chemical treatment with flocculating chemicals (e.g., aluminum and ferric chlorides) was also not effective. EXAMPLE 6 Two flat sheet membrane samples which have been soaked over a period of approximately 3 months in a representative mixture of alcohols were examined visually and then tested for salt rejection and flux using a standard brine solution at 225 psig (1.5 x 10 6 N/m 2 ). The two samples (i.e, Toray's SU-810 reverse osmosis membrane and Desalination Inc.'s nylon-based reverse osmosis membrane) both appeared physically intact (i.e., no change in color, no de-lamination, no change in appearance of the alcohol mixture itself and no loss in surface characteristics of the membranes) . The Toray membrane curled up more severely than the nylon-based membrane. However, upon rinsing it thoroughly in water, the membrane sample flattened out again. Even more importantly, after only a 24 hour test with 0.2% NaCl solution at 225 psig (1.5 x 10 6 N/m 2 ), the Toray membrane's salt rejection recovered to 95.5%, only slightly lower than the 97% rejection after 10 days of soaking in free alcohols. The salt flux from the soaked Toray membrane recovered to 7.1 gfd compared to 8.4 gfd obtained after the short soak test. It is likely that further improvements in the salt rejection and water flux might be obtained after further rinsing in water. In contrast, the Desal. nylon-based membrane recovered a flux of only 3.5 gfd and a salt rejection of only 83.5% after 24 hours, compared to 17.7 gfd and 97.4% rejection before exposure to the alcohol. These results offer further evidence of the Toray membrane's chemical compatibility, even upon prolonged exposure to the pure alcohols. However, it is not recommended to operate the reverse osmosis membrane system in the presence of a large concentration of free alcohol since the permeate quality will suffer as a result of membrane fouling. EXAMPLE 7 A GFT #1304 dehydration membrane (i.e., a polyvinyl alcohol crosslinked with maleic acid as the dense layer on top of polyacrylonitrile (PAN) porous sub-layer on a non-woven fabric) under pervaporating conditions was contacted with an ethanolic/water mixture to determine the amount of ethanol which permeates through the membrane together with water. The testing was run at 70°C with various cuts of feed, product, and permeate being collected. The results are set forth below in Table 6. Table 6 Wt% Ethanol Flux Run Time Sample Feed Permeate kg/m 2 - -hr (hours) 1 19.9 6.3 1.9 2 2 20.6 7.0 2.0 5 3 16.5 8.2 2.7 7 4 17.0 7.3 2.9 8 5 16.6 7.0 2.8 10 6 18.8 4.0 1.9 29 7 19.6 6.7 2.7 36 8 20.8 6.6 2.8 40 The GFT #1304 dehydration membrane exhibited high flux and a reasonable separation of ethanol from water. The amount of ethanol in the water permeate could probably have been reduced with the use of a more selective membrane which is also contemplated hereby. While we have shown and described several embodiments in accordance with our invention, it is to be clearly understood that the same are susceptible to numerous changes apparent to one skilled in the art. Therefore, we do not wish to be limited to the details shown and described but inrend to show all changes and modifications which come within the scope of the appended claims.

Claims: CLAIMS : 1. A method for treating an emulsified organic/aqueous effluent stream that comprises water, at least one metal complex and alcohol, said treatment comprises the steps of: separating said emulsified organic/aqueous effluent stream into an aqueous phase stream which comprises water, at least one metal complex, and residual alcohol and an organic phase stream which comprises alcohol, residual water and at least one metal complex; separating said aqueous phase stream into a metal and organic enriched stream and aqueous stream; recycling said metal and organic enriched stream to said emulsified organic/aqueous effluent stream; and discharging said aqueous stream. 2. The method according to claim 1 further comprising the steps of: separating said organic phase stream into an organic-rich stream and an organic-poor stream; and recycling said organic-poor stream to either said aqueous phase stream or said organic phase stream. 3. The method according to claim 1 wherein the separating of said emulsified organic/aqueous effluent stream into an aqueous phase stream and an organic phase stream takes place in either a phase separator or coalescer. 4. The method according to claim 3 wherein said phase separator is a gravity settling device. 5. The method according to claim 1 wherein the separating of said aqueous phase stream into a metal and organic enriched stream and an aqueous stream occurs by contacting a membrane separator with said aqueous phase stream. 6. The method according to claim 5 wherein said membrane separator includes a reverse osmosis membrane. 7. The method according to claim 6 wherein said aqueous stream permeates through said reverse osmosis membrane and said metal and organic enriched stream is the retentate. 8. The method according to claim 6 wherein the separating of said aqueous phase stream into a metal- enriched stream and an aqueous stream occurs at a pressure of between about 2.068 x 10 5 N/m 2 to about 1.379 x 10 7 N/m 2 . 9. The method according to claim 6 wherein said reverse osmosis membrane is a solvent resistant membrane. 10. The method according to claim 9 wherein said solvent resistant membrane is a polyamide-based membrane. 11. The method according to claim 10 wherein said polyamide-based membrane is an interfacially synthesized reverse osmosis membrane comprising a microporous substrate and an ultra-thin membrane covering the substrate, wherein the ultra-thin membrane comprises a crosslinked aromatic polyamide. 12. The method according to separating of said organic phase st. organic-rich stream and an organic-pe by contacting a membrane separator wit phase stream. 13. The method according to claim 1. membrane separator includes a pervaporatioi. 14. The method according to claim 13 whv organic-rich stream is the retentate and said t. poor stream is the permeate. 15. The method according to claim 13 wherein pervaporation membrane is selected from the group consisting of: polyvinyl alcohol (crosslinked or non- crosslinked) membranes, polyacrylate salt on polyethersulfone membranes, crosslinked composite of polysaccharide membranes, grafted polyethylene membranes, polypropylene membranes, poly(n- vinylpyrrolidone-co-acrylonitrile membranes, ion- exchange resin/pendant acid group membranes, and a membrane having a blend of polyvinyl alcohol, polyacrylic acid and nylon. 16. A method for separating an emulsified organic/aqueous effluent stream produced from a metal dialkyldithiophosphate synthesis process which comprises: separating said emulsified organic/aqueous effluent stream which comprises a metal complex, alcohols and water from a crude metal dialkyldithiophosphate product formed from said metal dialkyldithiophosphate synthesis process; separating said emulsified organic/aqueous effluent stream into an aqueous phase stream which comprises water, at least one metal complex, and residual alcohol and an organic phase stream which comprises alcohols, residual water and at least one metal complex; separating said aqueous phase stream into a metal and organic enriched stream and aqueous stream; recycling said metal and organic enriched stream to said emulsified organic/aqueous effluent stream; and discharging said aqueous stream. 17. The method according to claim 16 further comprising the steps of: separating as organic phase stream into an organic-rich stream and an organic-poor stream; recycling said organic-poor stream to either said aqueous phase stream or said organic phase stream; and recycling said organic-rich stream as a reactant in the synthesis of said crude metal dialkyldithiophosphate product. 18. The method according to claim 16 wherein the separating of said emulsified organic/aqueous effluent stream into an aqueous phase stream and an organic phase stream takes place in either a phase separator or coalescer. 19. The method according to claim 18 wherein said phase separator is a gravity settling device. 20. The method according to claim 16 wherein the separating of said aqueous phase stream into a metal and organic enriched stream and aqueous stream occurs by contacting a membrane separator with said aqueous phase stream. 21. The method according to claim 20 wherein said membrane separator includes a reverse osmosis membrane. 22. The method according to claim 21 wherein said aqueous stream permeates through said reverse osmosis membrane and said metal and organic enriched stream is the retentate. 23. The method according to claim 21 wherein said reverse osmosis membrane is a solvent resistant membrane. 24. The method according to claim 23 wherein said solvent resistant membrane is a polyamide-based membran . 25. The method according to claim 24 wherein said polyamide-based membrane is an interfacially synthesized reverse osmosis membrane comprising a microporous substrate and an ultra-thin membrane covering the substrate, wherein the ultra-thin membrane comprises a crosslinked aromatic polyamide. 26. The method according to claim 17 wherein the separating of said organic phase stream into an organic-rich stream and an organic-poor stream occurs by contacting a membrane separator with said organic phase stream. 27. The method according to claim 26 wherein said membrane separator includes a pervaporation membrane. 28. The method according to claim 27 wherein said organic-rich stream is the retentate and said organic- poor stream is the permeate. 29. The method according to claim 27 wherein said pervaporation membrane is selected from the group consisting of: polyvinyl alcohol (crosslinked or non- crosslinked) membranes, polyacrylate salt on polyethersulfone membranes, crosslinked composite of a polysaccharide membranes, grafted polyethylene membranes, polypropylene membranes, poly(n- vinylpyrrolidone-co-acrylonitrile membranes, ion- exchange resin/pendant acid group membranes, and a membrane having a blend of polyvinyl alcohol, polyacrylic acid and nylon. 30. The method according to claim 21 wherein the separating of said aqueous phase stream into a metal- enriched stream and an aqueous stream occurs at a pressure of between about 2.068 x 10 5 N/m 2 to about 1.379 x 10 7 N/m 2 . 31. A method for treating an emulsified organic/aqueous effluent stream that comprises water and alcohol, said treatment comprises the steps of: separating said emulsified organic/aqueous effluent stream into an aqueous phase stream which comprises water and residual alcohol and an organic phase stream which comprises alcohol and residual water; separating said aqueous phase stream into an organic enriched stream and aqueous stream; recycling said organic enriched stream to said emulsified organic/aqueous effluent stream; and discharging said aqueous stream. 32. The method according to claim 31 further comprising the steps of: separating said organic phase stream into an organic-rich stream and an organic-poor stream; and recycling said organic-poor stream to either said aqueous phase stream or said organic phase stream.

Inventors: BUTTS TIMOTHY JAMES, KORIN AMOS, BUTTS, TIMOTHY, JAMES, KORIN, AMOS
Applicants: EXXON CHEMICAL PATENTS INC, EXXON CHEMICAL PATENTS INC.
Application year: 1994
Main classification: C02F1
IPC codes: B01D17, B01D61, C02F1